Crimped Cap Rail - 1200 A
Non-Insulated Transit Crimped Cap Rails
The Conductix-Wampfler 1200 Ampere Crimped Cap Rail is a premium composite conductor rail designed for medium to light duty electrification applications in monorail, LRT, and APM systems. Engineered with a robust aluminum body and a durable stainless-steel contact cap, this rail has over 40 years’ proven service in a wide range of environments.
The 1200 Ampere Crimped Cap Rail has been applied in 2 pole DC traction power systems for APMs, LRTs and monorails. Rated at 1200 A, it delivers exceptional value with an electrical resistance below 24 µΩ/m, minimizing energy losses and maximizing efficiency in a compact profile. Its crimped cap design ensures reliable contact of the stainless-steel cap to the aluminum body for low interface resistance. The system meets EN50124-1 insulation standards for 750 VDC, guaranteeing safe and reliable operation in modern rail networks. This proven conductor rail solution supports various electrification configurations, including third rail, fourth rail and multi-pole systems.
Key Features and Benefits
- High Current Capacity: Rated at 1200 A continuous at 40°C, ideal for medium to light-duty transit applications.
- Low Electrical Resistance: Below 24 µΩ/m at 20°C, ensuring excellent energy efficiency.
- Premium Materials:
- 300 series stainless-steel contact cap for durability and corrosion resistance.
- 6000 series aluminum alloy for exceptional electrical conductivity and mechanical strength.
- Optional Insulating Covers available in NFPA 130 compliant PC-ABS alloy for high durability and weatherability.
- Low Interface Resistance: Reliable contact between the aluminum conductor and stainless-steel cap provides efficient power transfer.
- State-of-the-Art Manufacturing: Advanced production processes and quality systems deliver high product quality at a competitive cost.
- Precision Engineering: Automated drilling and cutting ensure accurate fit and seamless integration with accessories.
- Versatile Applications: Suitable for third rail, fourth rail, and multi-pole systems in LRT, APM, and monorail networks.
- Specification
- Accessories
- High Quality Manufacturing
- 2-Pole System Setup
Specification
| Parameter | Value | Unit |
| Resistance | 23.8 (7.25) | µΩ/m (µΩ/ft) |
| Height | 74.8 (2.94) | mm (in) |
| Head Width | 30 (1.18) | mm (in) |
| Foot Width | 25 (.98) | mm (in) |
| Length | < 12.2 (40) | m (ft) |
| Cross-Section | 1,500 (2.326) | mm2 (in2) |
| Linear Weight | 4.55 (3.05) | kg/m (lb/ft) |
Accessories
Support Insulator Assembly
- Suitable for side contact system configuration
- Meets all applicable mechanical and electrical standards
- Designed to withstand all static and dynamic mechanical stresses
- Withstands all vertical, horizontal, and longitudinal forces from conductors and current collection devices
- Maintains contact surface of the conductor rail relative to the Top of Rail (TOR) for optimal current collector contact
Power Feed / Cable Terminal Assembly
- Connects conductor rails to substation feeders and across gaps at ramps
- Plates are pre-drilled from a single piece of aluminium of uniform cross-section with no welds. This maintains a low resistance connection from the feed cable to the conductor rail.
- Hole size and spacing can be adapted to meet cable lug geometry
- Designed to minimize heat rise due to current flow
Ramps
- Designed to ensure smooth pickup of the collector shoe and transition to the conductor rail.
- Exceptionally Durable: Precision manufactured from a solid steel section and hot-dip galvanized per ASTM A123 for superior corrosion resistance.
Splice Joint Assembly
- Electrical resistance below 24 µΩ/m at 20°C
- 300 Series stainless-steel hardware for corrosion-resistance and durability
Anchor Assembly
- 300 Series stainless-steel hardware for corrosion-resistance and durability
Expansion Joint Assembly
- Provides electrical and mechanical continuity
- Length: 2 m
- Stroke Length: 1 × 250 mm
- Service life: 40 years (15 000 cycles)
PC-ABS Cover System
- Suitable for indoor or outdoor use
- Fire resistant, UL94 V0 and NFPA 130 compliant
- Provides protection against incidental (top) contact
- High resistance to shocks, water, chemicals, and corrosive environments
- Located outside the train’s dynamic gauge to prevent interference with rolling stock
High Quality Manufacturing
Our precision production line for crimped cap transit rails is designed to deliver consistently high-quality systems with tight tolerances. Precisely controlled and fully reproducible manufacturing processes ensure that every conductor rail and accessory meets defined specifications and performance requirements.
By minimizing manual intervention, process variability, errors, and scrap are significantly reduced. Integrated inline inspection systems and sensor-based monitoring continuously verify critical quality parameters throughout production.
Your benefit: You receive reliable crimped cap rail systems with consistent electrical and mechanical performance, supporting long service life and dependable operation in demanding environments.
2-Pole System Setup
A well-designed conductor rail system ensures a reliable and uninterrupted power supply under the heaviest train operations. Optimized system design and robust components provide high system availability, minimize downtime, and support efficient train operations.
